Group Lead, Aircraft Integration - Additive Manufacturing

Job Overview

The Group Lead, Aircraft Integration - Additive Manufacturing - is responsible for overseeing and coordinating additive manufacturing and aircraft integration for our unmanned aircraft systems. This leader will manage the end-to-end 3D printing operation - from machine scheduling and material preparation through post-processing and quality checks - and direct the assembly and integration of additive manufactured UAS platforms. The ideal candidate is highly organized, technically strong, and comfortable leading a fast-paced production team building cutting-edge unmanned aircraft. They lead a team of technicians ensuring that all integration activities are completed on time, within budget, and in accordance with quality standards and regulatory requirements.

Essential Functions

• Lead and supervise the additive manufacturing and aircraft integration team responsible for 3D printing, post-processing, airframe assembly, and system integration.
• Manage daily 3D printing operations including machine setup, print monitoring, material handling, maintenance coordination, and troubleshooting of additive manufacturing equipment.
• Direct the mechanical and electrical assembly of unmanned aircraft components, including installation and checkout of airframe structures, avionics, wiring, payload components, and other electronic systems.
• Monitor production activity across printing and assembly; identify process issues, conduct root cause analysis, and implement corrective and preventive actions.
• Oversee cable routing, cable harness assembly, testing, and repairs associated with aircraft builds.
• Ensure all printed components and assemblies meet engineering specifications, quality standards, and functional requirements.
• Coordinate staffing, work assignments, and production sequencing to maximize throughput and meet demanding delivery schedules.
• Track performance against production targets and provide coaching, direction, and performance feedback to the team.
• Drive continuous improvement in additive manufacturing and assembly processes, documentation, and workflows.
• Serve as a technical knowledge resource for additive manufacturing methods, materials, and UAV assembly best practices.
• Support hands-on troubleshooting, rework, maintenance, and final aircraft checkout as needed.
• Perform other duties as required to support production and program needs.
• Regular and reliable attendance on a full time basis [or in accordance with posted schedule].
• Responsible for exhibiting professional behavior with both internal and external business associates that reflects positively on the company and is consistent with the company's policies and practices.
• Embodies AEVEX's cultural values and aligns daily actions with department goals and company culture.

Qualifications and Competencies

List skills, knowledge and attributes in the qualifications and competencies section. Review the leadership competencies and edit for the department name.

Qualifications and Competencies

• Demonstrated leadership experience directing small teams or production cells.
• Strong understanding of manufacturing workflows, quality control, and production documentation.
• Ability to troubleshoot mechanical, electrical, and print-process issues.
• Proficiency reading engineering drawings, wiring diagrams, and assembly instructions.
• Strong organizational and communication skills.
• Knowledge of CAD tools, slicing software, and printer maintenance best practices preferred

Leadership Competencies

• Directs and provides expert knowledge in the day-to-day function of the department.
• Identifies, recruits, and retains top-notch talent.
• Champions AEVEX's culture and empowers employees to take responsibility for their jobs and goals.
• Coaches, mentors, engage and develop the team, including overseeing new employee onboarding and providing career development planning and learning opportunities.
• Sets performance standards and encourages employee engagement and results through delegation, continuous feedback, goal setting, and performance management.
• Maintains transparent communication. Appropriately communicates organization information through department meetings, one-on-one meetings, and appropriate email, and regular interpersonal communication.
• Provides oversight and direction to the employees in accordance with AEVEX's policies and procedures.

Education / Certifications

• High school diploma or equivalent required.
• Bachelor's Degree Preferred

Experience

• 5+ years of experience in aircraft assembly/fabrication/structures
• 1+ years of supervisory experience
• Proven working experience working on integration, fuselage/airframe, programming, checkout and GCS portions of a UAV or similar aircraft.
• Experience in additive manufacturing or 3D printing operations (FDM, SLA, SLS, or similar).
• Experience in mechanical or electrical assembly of unmanned systems, aircraft, robotics, or related platforms.
• Preferred Qualifications:
  • Experience leading an additive manufacturing team or production line.
  • Hands-on experience with large-format printers or high-throughput 3D print operations.
  • Background in UAV integration, flight hardware, or aerospace manufacturing environments.
  • Experience with lean manufacturing, continuous improvement, or process optimization.
  • IPC certification, soldering skills, or cable harness experience.

Physical Requirements

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. While performing the duties the employee is:

Physical Requirements

• Frequently required to sit, and to reach to use computers and other office equipment
• Occasionally required to lift up to 15 pounds
• Occasionally required repetitive movements of wrists, hands, and/or fingers

Note: For the purpose of this summary, occasionally is used to represent up to 1/3 of the time given to the work day, frequently represents 1/3 to 2/3 of the time and constantly represents 2/3 or more of the time.

Security Clearance

• Ability to obtain/maintain a Secret DoD clearance, U.S. Citizenship required.

Disclaimer

AEVEX Aerospace is an Equal Opportunity employer. We are committed to providing equal employment opportunities to all employees and applicants without regard to race, religious creed, color, sex (including pregnancy, breast feeding and related medical conditions), gender, gender identity, gender expression, sexual orientation, national origin, ancestry, citizenship status, military and veteran status, marital status, age, protected medical condition, genetic information, physical disability, mental disability, or any other protected status in accordance with all applicable federal, state and local laws.

About AEVEX

AEVEX, headquartered in Solana Beach, California, supports the U.S. national security mission and partner nation needs around the world by providing full-spectrum aviation, remote sensing, and analysis solutions. The company's capabilities include custom design and engineering; rapid prototyping; sensor integration and sustainment; aircraft modification and certification; flight test instrumentation and support; mission operations service; advanced intelligence data processing, exploitation, and dissemination solutions; and tailored hardware and software mission-system tools. AEVEX uses agile and customized approaches to rapidly define, develop, and deliver specialized solutions for airborne special mission needs for the U.S. Government, partner nations, and commercial businesses. AEVEX has major offices in California, Florida, North Carolina, Ohio, and Virginia.

AEVEX provides a full suite of comprehensive benefits, including a 401(k)-retirement plan, comprehensive Medical, Dental, Vision, Disability and Life insurance group coverage with a portion of the premiums paid by the company, professional development funds, and an Employee Assistance Plan (EAP) with counseling, legal help, child and elder care support, among other benefits.

Equal Employment Opportunity:

AEVEX is an Equal Opportunity employer. We are committed to providing equal employment opportunities to all employees and applicants without regard to race, religious creed, color, sex (including pregnancy, breast feeding and related medical conditions), gender, gender identity, gender expression, sexual orientation, national origin, ancestry, citizenship status, military and veteran status, marital status, age, protected medical condition, genetic information, physical disability, mental disability, or any other protected status in accordance with all applicable federal, state and local laws.

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